Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/06—Quartz; Sand
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/26—Carbonates
  • C04B14/28—Carbonates of calcium
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/38—Fibrous materials; Whiskers
  • C04B14/42—Glass
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B16/02—Cellulosic materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B16/04—Macromolecular compounds
  • C04B16/06—Macromolecular compounds fibrous
  • C04B16/0675—Macromolecular compounds fibrous from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/2623—Polyvinylalcohols; Polyvinylacetates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/2641—Polyacrylates; Polymethacrylates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/38—Polysaccharides or derivatives thereof
  • C04B24/383—Cellulose or derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
  • C04B28/141—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing dihydrated gypsum before the final hardening step, e.g. forming a dihydrated gypsum product followed by a de- and rehydration step
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
  • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
  • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
  • C04B2111/0062—Gypsum-paper board like materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
  • C04B2111/1006—Absence of well-defined organic compounds
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• the present invention relates to the field of gypsum-based materials, more specifically to the field of gypsum-based panels.
• Light-weight panels such as plasterboard (e.g. gypsum plasterboard), polystyrene board and fibreboard are commonly used to provide partitions within buildings. Their advantages for this application include the fact that they are light and quick to install.
• such light-weight panels may have the drawback that they are not strong enough to support fixtures (e.g. sinks, televisions, radiators, fire extinguishers, shelves and any other item that requires attachment to the panel).
• the weight of the fixture may cause the fixing means (e.g. screws) to be pulled out of the panel, such that the fixture falls away from the partition.
• the plywood sheet is provided on the side of the panel opposite to that on which the fixture is to be located.
• the plywood sheet may provide increased strength for retaining one or more fixing means (e.g. screws) employed to secure the fixture to the panel.
• the plywood sheet is positioned within the partition framework, and the plasterboard then fixed to the plywood, so that it lies outside the partition framework.
• metal support means may be provided. These may comprise fixing plates, channels, straps, or metal fasteners.
• the metal support means are generally positioned on the side of the panel opposite that to which the fixture is to be secured, and act to receive and secure fixing means, e.g. fixing screws, that are used to attach the fixture to the panel.
• the present invention may provide a panel having a gypsum matrix, the gypsum matrix having the following additives embedded therein:
• a synthetic polymeric binder in an amount greater than 4wt% relative to the gypsum; ⁇ the glass fibre and synthetic polymeric binder being present in a weight ratio of at least 2 parts binder to one part fibre;
• the amount of sand present in the gypsum matrix lies in the range 0-0.5 wt% relative to the gypsum;
• the amount of cellulosic fibre present in the gypsum matrix lies in the range 0-10 wt% relative to the gypsum.
• the polymeric binder is polyvinyl acetate.
• the amount of acrylic resin present in the gypsum matrix lies in the range 0-1 wt% relative to the gypsum.
• the gypsum matrix is substantially free from acrylic resin.
• the amount of calcium carbonate present in the gypsum matrix lies in the range 0-5 wt% relative to the gypsum, more preferably 0-1 wt% relative to the gypsum.
• the gypsum matrix is substantially free from calcium carbonate.
• the gypsum matrix is substantially free from sand.
• the amount of cellulosic fibre present in the gypsum matrix lies in the range 0-1.5 wt% relative to the gypsum, more preferably 0-1 wt%.
• the gypsum matrix is substantially free from cellulosic fibre.
• the term "cellulosic fibre” is intended to refer both to fibres that are provided within wood particles (such as wood chip and fine sawdust particles) and to fibres that are no longer bound by the natural binders present in wood.
• the amount of wood particles present in the gypsum matrix lies in the range 0-2 wt% relative to the gypsum, preferably in the range 0-1.5 wt%, more preferably in the range 0-1 wt%.
• the total weight of the additives embedded in the gypsum matrix is less than the weight of the gypsum in the gypsum matrix. That is, gypsum is preferably the principal component of the panel by weight.
• the polymeric binder is present in an amount greater than 3.5wt%, preferably greater than 4wt%, most preferably greater than 5wt% relative to the gypsum. It has been found that the addition of polymeric binder results in continued improvements to mechanical properties, at least up to levels of about 25 wt% binder relative to the gypsum. Thus, in view of the relatively high cost of synthetic polymeric binders, it is generally preferred that the levels of synthetic polymeric binder should be 25wt% or less relative to the gypsum.
• the glass fibres embedded in the gypsum matrix were originally added to the gypsum slurry used to form the panel. Thus they are dispersed throughout the gypsum matrix, preferably in a substantially even distribution.
• the glass fibre is present in an amount greater than 1.5 wt% relative to the gypsum.
• the glass fibre is preferably present in an amount of less than 6 wt% relative to the gypsum.
• the glass fibres have an average length in the range 3-10mm.
• the glass fibres have an average diameter in the range 5-50 micron.
• the glass fibre and polymeric binder are present in a weight ratio of at least 2.5 parts binder to one part fibre, preferably at least 3 parts binder to one part fibre, preferably at least 4 parts binder to one part fibre.
• the panel may be substantially free of starch. In other words, the panel may be substantially free of starch.
• the panel may contain both synthetic polymer and starch, the starch being present in a lesser amount than the synthetic polymer, preferably in an amount of less than 5wt% relative to the amount of synthetic polymer, more preferably less than 3wt% relative to the amount of synthetic polymer.
• gypsum matrix does not include any fibres other than glass fibres.
• the average length of the non-glass fibres is preferably at least 50% of the average length of the glass fibres, more preferably at least 80%.
• the panel is provided with facings on one or both sides.
• the facings may be e.g. paper facings, which may comprise cellulose and optionally glass fibres.
• the facings may be provided by a mat partially or fully embedded at the surface of the panel, for example, a glass fibre mat.
• the inclusion of synthetic polymer to strengthen the panel, rather than starch, may have one or more of the following advantages:
• the finished panel shows less dimensional variation with changing humidity.
• the panel has a thickness in the range 6-20mm, more preferably 10-16mm.
• the panel has a density in the range 600-1400 kg/m 3 , more preferably in the range 700-1200 kg/m 3 .
• the present invention may provide a method of making a panel according to the first aspect of the invention, comprising the steps of providing a stucco slurry comprising glass fibres and a synthetic polymeric binder, and allowing the slurry to set, wherein the amount of lime present in the slurry lies in the range 0-0.5 wt%; and further wherein the step of providing the stucco slurry comprises adding water to stucco in an amount that is less than twice the weight of the stucco.
• the slurry is substantially free from lime.
• water is added to the stucco in an amount that is less than 1.5 times the weight of the stucco.
• the panel prepared through the method of the second aspect of the invention may comprise one or more optional features of the panel according to the first aspect of the invention.
• Gypsum plasterboards were prepared from gypsum slurries, according to the following method:
• Polyvinylacetate (Vinamul 8481 from Celanese Emulsions) is added to water to form an aqueous suspension;
• Stucco is added to the aqueous suspension to form a slurry
• the slurry is mixed in a Kenwood blender (RTM) at minimum speed for 10 seconds;
• the slurry is deposited on a forming surface to form a board
• the board is dried at a temperature of 160°C for one hour, and further at a
• the board is conditioned at 23°C and a relative humidity of 50% until a constant weight is achieved.
• Polyvinylacetate is added to the slurry in the form of an aqueous suspension.
• the amount of polyvinylacetate set out in Table 1 refers to the amount of polyvinylacetate contained within the aqueous suspension, rather than the total mass of the suspension added to the slurry.
• Screw pull-out tests were carried out on samples measuring 100mm by 100mm that had been conditioned at a temperature of 23°C and a relative humidity of 50%.
• a 50mm single thread wood screw was inserted into the sample using a torque screwdriver, the screw passing through a metal load transfer element positioned on the surface of the sample.
• the load transfer element has a first portion that is configured to lie between the screw head and the surface of the sample, and a second portion that is configured to engage with a testing machine so as to allow a load to be applied to the screw along the axis of the screw.
• the specimen was then mounted in a Zwick Universal Testing Machine and a 10N pre-load applied to the screw along the axis of the screw. Subsequently, the load was increased by setting a constant cross-head speed of 10mm/minute until pull out was achieved.
• Refix pull-out tests were carried out using the same protocol as the screw pull-out tests, with the additional step, immediately after the step of inserting the screw into the sample using a torque screwdriver, of removing the screw and reinserting it in the same position using the torque screwdriver. Fatigue tests
• Fatigue tests were carried out using the same protocol as the screw pull-out tests, with the additional step, between the steps of applying a 10N pre-load to the screw and setting a cross-head speed of 10 mm/minute, of applying 100 loading cycles between 10N and 300N at a cross-head speed of 10mm/minute.
• Hand torque tests were carried out on samples measuring 100mm by 100mm that had been conditioned at a temperature of 23°C and a relative humidity of 50%.
• a 50mm single thread wood screw was inserted into the sample using a screw gun, the screw passing through a steel washer positioned on the surface of the sample.
• the screw gun was configured to cut out when the screw had been inserted into the sample to such a depth that the head protruded by 10 mm from the sample.
• the screw was then turned using a torque-controlled manual screwdriver until a sharp increase in the torque reading was observed, as the screw head came into contact with the sample.
• the screw was then turned further in increments of 1/8th of a turn, the torque reading being recorded after each increment and then being re-set to zero. This process was continued until at least 1.5 turns after a maximum torque had been achieved. The maximum torque was then recorded.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Panels For Use In Building Construction (AREA)
• Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Environmental & Geological Engineering (AREA)

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• 2017
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